Marine Fender and Method of Assembly of Components of Same

ABSTRACT

This invention relates to a marine fender and a method of assembly of the components of said marine fender. The fender is comprised of a plurality of components that are conjoined with mating edges ( 15 ) and a self-holding tapered wedge ( 20 ). Preferably, the components are made from resilient material that is suitable for compression molding, and are approved for use in the marine environment. One preferred embodiment of the invention encircles a single piling (FIG.  1 ). The fender can be positioned to float with changing water levels, and rotate upon impact. The marine fender can be installed on existing isolated and independent marine structures with little or no modification of the structure.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No. 62/044,441, filed Sep. 2, 2014.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The claimed invention relates to a marine fender for absorption, deflection, or dissipation of kinetic impact energy that occurs when a waterborne vessel engages with a piling, dock, or other marine structure, and the method of assembly of components of same marine fender.

2. Description of Related Art

There are marine structures in use today, including but not limited to monopiles, breasting dolphins, turning dolphins, or docks that remain inadequately protected from kinetic impact energy of waterborne vessels. Some of the above mentioned marine structures cannot be modified to accommodate proper installation of existing marine fender options. Some fenders that can be readily installed lack durability to sustain repeated engagements, or lack capacity for absorption, deflection, or dissipation of large amounts of kinetic impact energy generated by barges, container ships, tugs and other vessels. Therefore, the need remains to develop effective marine fender that can be readily applied to certain existing marine structures.

Unified Facilities Criteria (UFC) published by the Department of Defense (Design: Piers and Wharves, UFC 4-152-01, Chapter 5: Fender Systems, pp. 99-134, Washington, D.C. 2005) describes a fender system as a marine structure of fender pilings and marine fenders that converts kinetic impact energy of a berthing vessel into potential energy in the fender system material. Fender piles, or pilings, that are made from steel, concrete, composite, etc., and marine fenders are foam-filled, solid rubber, or pneumatic. The pilings are known to be stiff and lack the capacity for large deflection which results in high reaction loads and frequent breakage of piling and hull damage, and often are combined with one or more types of marine fenders.

U.S. Pat. No. 3,173,270 of Blancato informs that many fender systems have been proposed, but have not gone into extensive use for various reasons, for example, high initial costs, difficulty of application to existing marine structures, costly maintenance, and inadequate energy absorption properties.

U.S. Pat. No. 3,950,953 of Matthews describes locally-found fender materials used on pilings, such as discarded fire hose, tires, or other similar materials. The locally-found materials have inadequate capacity for absorption of kinetic impact energy. Additionally, there are emerging environmental concerns of the long term use of tires in or around sensitive marine habitats.

One of the most common marine structures found throughout the world is a monopile. As the name infers, it is a single piling of timber, steel, composite or other material. The monopile is easy to install in water depths ranging from 0-30 meters. Marine Fender International of Willimington, Calif. trademarked Ocean Guard™ Monopile Donut Fender in Feb. 2015. The trademark registration reports it was first used in commerce Jun. 21, 2004. The donut fender is described in marketing collateral as a one-piece, foam-filled cylinder with “donut” hole in the center of the fender through which a piling is inserted. The donut fender rotates upon impact. The donut fender slides up and down with changing water levels with the aid of UHMW bearing pads located on the inner diameter of the fender. UHMW is ultra high molecular weight polyethylene that is abrasion resistant. Upon repeated impact, the donut fender is known to catch on the piling, and loses its ability to float or rotate. When the donut fender is in this caught position, the outer skin of the cylinder becomes more vulnerable to damage from a passing vessel.

Other related marine structures are the breasting and turning dolphins. Dolphins are isolated, man-made marine structure typically consisting of a number of pilings driven into the seabed or riverbed and connected above the water level. Breasting dolphins are sometimes used for roll-on roll-off facilities. Breasting dolphins assist in berthing of vessels by taking up some berthing loads and keep the vessel from pressing against the pier structure. They are also commonly used near pier structures to control the transverse movement of berthing vessels. A turning dolphin is an isolated structure used solely for guiding the ships into a berth or away from known obstructions. Approach dolphins are used where the end of a pier or ends of a slip require protection from incoming ships.

Rubber tires are known to be used in monopile, dolphin, or other fender systems. Many tires used for marine fenders are recycled heavy equipment tires. Recycled tires are known to have lower values of tensile strength and elongation at break that affects their ability to absorb kinetic energy due to impact. Tires are known to have poor resistance to UV and lose flexibility in low temperatures. Tires in the water swell, “roll up”, tear, abrade, and show other forms of damage that affects usefulness as marine fenders. Most common installation attaches the tire to the piling so it does not float with the changing water level. Therefore, tires must be stacked to cover a range of point of impact possibilities or strike points, which can be present when a vessel comes into berth. When the piling that supports the tire stack is in need of repair, the tire stack is removed with costly and time consuming procedure. Sometimes repair work also involves dismantling the dolphin in order to get to the tires. Tires absorb water and become heavy, and if mishandled the tires will sink to the bottom of the waterway, becoming a source of pollution.

U.S. Pat. No. 5,957,073 of Kerber and Armfield describes a dampening and shield bumper of resilient laminated loops that is a highly adaptable general fender for structures subject to contact or collision with other structures or objects, such as ships, barges, tugboats and the like. The patent is assigned to Schulyer Rubber Company, Inc. of Woodinville, Wash., which markets “Dolphin Pipe Pile Fenders/Schulyer Rub Face Model 153” based on the shield bumper of '073. Market applications include ferry landings, barge mooring dolphins, landing dolphins, etc. Model 153 can be welded, bolted, or clamped to steel dolphin pilings, or bolted or clamped to concrete pilings. Model 153 comes in a range of sizes from 12″ to 120″ in vertical height, and 120° to 180° of coverage of the outer surface of the pilings. The shield bumper is made from recycled tire material that is attached to a steel frame. While the Dolphin Pipe Fender accommodates isolated marine structures, it lacks capacity for impact energy absorption. Because of this lack of capacity, Maritime International of Broussard, Louisiana recommends application of the shield bumper where impact energy absorption is not required. Similar to tires, the bumper shield cannot float with the changing water levels and must cover the range of possible strike points of a berthing vessel or barge. Repair or maintenance is not easy or cost-effective as the rubber strip is bolted or otherwise fixed to a heavy steel frame, and entire frame must be replaced.

Prior art examples of marine fenders comprising modular components recite improvements, which make installation, inspection, repair, or maintenance easier and cost-effective. U.S. Pat. No. 5,018,471 of Stevens teaches a marine fender that includes an elongated bumper side to cushion normal impact and a high-friction mounting surface to reduce slippage between the fender and the piling. The strap at the lateral sides of the fender body encircles the piling for selectively securing the fender to the piling such that the mounting surface is held thereto in frictional contact. The strap also provides means for quick installation or removal.

U.S. Pat. No. 7,617,792 of Pursley describes several devices in the prior art that are used for protecting posts and pilings from impact and their significant disadvantages. For instance, a glancing blow tends to peel the bumpering device off the post or move it circumferentially from its original position. It is one object of '792 to provide a hollow core bumper that can be split along one side or provided in two halves and placed over a piling or post to absorb impact forces effectively from multiple directions with a protective liner to assist its rotation and retaining ring to hold the bumper in place vertically. The bumper and its protective liner can be stacked, one upon the other.

U.S. Pat. No. 8,979,436 of Goodman recites a watercraft bumper with a sleeve to connect to a piling and a slit in the sleeve that includes a biasing device to open and close the slit. In references cited, the examiner included U.S. Pat. No. 7,617,792 of Pursley.

The above-mentioned patents, '471, '792, or '436, have not been observed in application on marine structures or in fender systems where large forces are at work from heavy-tonnage vessels and barges.

The subject of this patent application has a preferred embodiment related to a pneumatic fender, therefore prior art should include pneumatic marine fenders. Pneumatic marine fenders are described in U.S. Pat. No. 4,296,705 assigned to Bridgestone Tire Company, Ltd of Japan. The fender is a cylindrical barrel serving as a shock receiving face. The barrel comprises a hollow shell formed of rubber or rubber-like elastic material. While the pneumatic fender excels at absorbing impact energy, it is susceptible to premature puncturing and therefore, is heavily reinforced with chain netting and recycled tires. The pneumatic fender is unable to support consistent stand-off distance from the pier or dock as the impact load affects compression. Another drawback is that over time, water seeps in around the shackles of the fender, making them very heavy and cumbersome for seasonal maintenance and must be drained before storage. Yet another drawback, when damaged, the pneumatic fender must be completely removed for repair, and the berth becomes inactive for a substantial period of time. Costs of an inactive berth must be considered in addition to fender repair or replacement.

The shortcomings of current fender technologies demonstrate a considerable need for improvement in the marine fender art especially for marine structures such as monopiles, breasting dolphins, turning dolphins, and docks. Additional considerations for improvement include simplicity of manufacturing and assembly, environmental friendliness in respect to materials suitable for marine environments, and costs to install, inspect, maintain, or repair.

The inventor, a tool maker by trade, was approached in 2010 by Washington State Maritime Industry facility managers and administrators to consider an improved marine fender. The improvement would be a fender that is simple to use and produce. Another consideration is that the fender installation would not require structural changes to existing marine structures. Preferred material is approved for use in marine habitats. The improved fender is cost-effective and environmentally-sound to install, inspect, maintain, or repair.

The claimed invention is marine fender which is specifically advantageous to compression-molded manufacturing using resilient material. One consideration for resilient material is ethylene propylene diene terpolymer or EPDM, which is a synthetic elastomer. The preferred embodiment is a no-zinc formula EPDM that is currently approved for use in marine environments, such as a propriety EPDM produced by M & R Profiles of Seligenstadt, Germany, which the inventor has secured exclusive licensing rights for the purpose of manufacturing marine products. The proprietary EPDM complies with the European Union's REACH regulations. The proprietary EPDM has excellent properties of durability, UV resistance, tear resistance, and abrasion resistance.

Prototype construction of this marine fender was requested by Washington State Department of Ecology under contract #C1500137 in partnership with the Governor's Office for Maritime Industry and the Port of Seattle. The claimed invention is also the subject of the inventor's application to the National Science Foundation's Small Business Innovation Research for Phase I funding, NSF Proposal #1548868.

BRIEF SUMMARY OF THE INVENTION

The claimed invention is a marine fender and preferred assembly method of components of the marine fender. One object of the invention is to provide an improvement over prior-art technology. A special object of this invention is to provide improved marine fender options for isolated and independent marine structures, such as monopiles, or dolphins.

The claimed invention is easy to install around a single piling without having to remove or otherwise alter the piling from its position. The components are cost-effective to inspect, replace, or repair. The invention can be produce in various sizes and thicknesses for use and applications in variety of fender systems, locations, and orientations, such as marinas, docks, shipyards, quays, shipping channels, and floating and fixed offshore foundations.

One preferred embodiment of the invention, a floating fender, can be utilized as a platform to attach self-generating lights, scientific measuring devices, or other devices.

The above and further objects of the claimed invention will become more readily apparent upon consideration of the following specification describing preferred embodiments of the invention, and of the drawings accompanying the specification and forming a part thereof, or may be learned through practice of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a view of a preferred embodiment as a floating fender.

FIG. 2 is an exploded view of preferred mode of installation around a piling.

FIG. 3 is a view of the articulation from the inside wall of the fender.

FIG. 4 is an exploded view of an interlocking section.

FIG. 5 is an exploded view of a self-holding tapered wedge.

FIG. 6 is a cross-section view of the assembly belt track.

FIG. 7 is a view of a preferred embodiment using an end piece.

FIG. 8 is a view of a preferred embodiment as a hanging fender.

DETAILED DESCRIPTION OF THE DRAWINGS

FIG. 1 is a view of a preferred embodiment of the claimed invention as a completely assembled fender 100 encircling a piling 500. The fender comprises a plurality of components that are conjoined with mating edges 15. An assembly belt, preferably an environmentally friendly polymer, can circumscribe the completely assembled fender 100. The assembly belt can be secured with a buckle with cover. The components and buckle cover are compression-molded using a resilient material such as EPDM. It is preferred that the resilient material be approved for use in marine environments.

One preferred mode of installation for a floating fender is shown in FIG. 2. The interlocking sections 10 are conjoined at the mating edges 15, which forms a tapered mortise 25. Then, a self-holding tapered wedge 20 is then inserted into the tapered mortise 25. When all components are in place, the completely assembled fender can be circumscribed with a polymer assembly belt that is fastened with a buckle with buckle cover.

Preferred dimensions of the completely assembled fender 100 can be 10 inches high (S.I. 25.4 cm) with 20 inches (S.I. 50.4 cm) inner diameter to accommodate a piling with a 14 to 18 inches (S.I. 35.56 cm to 45.72 cm) outer diameter. This allows for a space 2 to 6 inches (S.I. 5.06 cm to 15.24 cm) between the inner wall of the fender and the outer surface of the piling, creating an hydraulic cushion that aids in deflection of impact energy and rotation of the fender about the piling. The outer diameter of the fender 100 can be 44 inches (S.I. 111.76 cm).

FIG. 3 views a preferred method of assembly that enables an articulation 60 in the tapered mortise 25 between mating interlocking sections 10. When kinetic impact energy 80 is applied, the mating edges 15 can react with convergent movement 70 at the point of impact and divergent movement 71 along the inner wall of the fender.

FIG. 4 is an exploded view of a preferred assembly method of a component that fastens the interlocking section top half 11 to its identical bottom half 12 by introducing one-side of double-tongued mechanical seal cord 30 into a groove 31 present in one half and the other side of said seal cord 30 into the a groove 31 present in the identical half. Then pressure is applied to outer surface of each half, the cord 30 compresses and slips into the groove 31. When pressure is relieved the cord 30 regains its shape inside the groove 31. The fastening can be adhesively enhanced.

FIG. 5 is an exploded view of a preferred assembly method of a component that fastens the self-holding tapered wedge top half 21 to its identical bottom half 22 by introducing one-side of double-tongued mechanical seal cord 30 into a groove 31 present in one half and the other side of said seal cord 30 into the a groove 31 present in the identical half. Then pressure is applied to outer surface of each half, the cord 30 compresses and slips into the groove 31. When pressure is relieved the cord 30 regains its shape inside the groove 31. The fastening can be adhesively enhanced.

FIG. 6 shows that the interlocking section 10 can have an assembly belt track with a continuous raised rib-like boss 50 that is recessed into the interlocking section 10, and said boss 50 convergently reinforces the mechanical seal 30 when secured with an assembly belt and buckle with buckle cover.

FIG. 7 views another preferred embodiment of the claimed invention as a piling protector 300. Components comprise a member on the left 41 and a member on the right 42, each with a mating edge 15 proximate to the interlocking section 10. The self-holding tapered wedge 20 is inserted in the tapered mortise 25 between interlocking sections 10 and members. The member on the left 41 and the member on the right 42, each have an imbedded steel strap 45 that can be wrapped around a piling 500 and fastened with a bolt. The piling protector 300 can be secured with an assembly belt and buckle with buckle cover.

FIG. 8 shows yet another preferred embodiment of the claimed invention as a hanging fender 700. Completely assembled fender 100 with assembly belt, buckle and buckle cover encircle a steel pipe 90 that is reinforced with rebar. The end caps 91 have a shackle for mounting fender with chains on a sea wall, dock face, or berth. The steel pipe and shackle can be treated for installation in the marine environment. Said treatment can be galvanized, can be painted, or otherwise treated to mitigate leaching of zinc and other pollutants in the marine environment.

The interlocking section, self-holding tapered wedge, other member, buckle cover, and mechanical seal cord are comprised of a resilient material, which can be a synthetic elastomer, and can be certified as environmentally friendly

The preferred assembly belt can be fitted with an elastomer extrusion that is comprised of a non-scuffing, environmentally-friendly elastomer, which extends beyond the circumference of the fender assembly to function as a rub-rail.

Although the claimed invention has been described in detail in connection with the exemplary embodiments, it should be understood that the invention is not limited to the above disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alternations, substitutions, or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention.

There are of course many variants, and all such variants are contemplated. Accordingly, the claimed invention is not limited by the foregoing description or drawings, but is only limited by the scope of the appended claims. 

What is claimed is:
 1. A marine fender for absorption, deflection, and dissipation of kinetic impact energy resulting from a waterborne vessel berthing or otherwise engaging contact with a marine structure, and a method of assembly of the components of the same, comprising: a plurality of interlocking sections with mating edges; a plurality of other members with mating edges; a plurality of self-holding tapered wedges conjoining said interlocking sections or other members one to another.
 2. The method of assembly of the components of the marine fender of claim 1 comprises: providing a mold for interlocking section half with cavities for internal air pockets, and with groove to accept and secure one side of a double-tongue mechanical seal cord. providing a mold for self-holding tapered wedge half with cavities for internal air pockets, and with groove to accept and secure one side of a double-tongue mechanical seal cord. providing a mold for other member half with at least one end that is with mating edges with groove to accept and secure one side of a double-tongue mechanical seal cord. The other member half can be with air cavities. fastening the interlocking section half each half to its identical half by introducing one-side of double-tongued mechanical seal cord into a groove present in one half and the other side of said tongue into the a groove present in the half. The self-holding tapered wedge and other member are fastened in the same manner. securing the fender system with an assembly belt and buckle introduced into the assembly belt track of said interlocking sections or other members.
 3. The preferred method of assembly of claim 2 enables an articulated joint between a mating interlocking section or another member when the self-holding tapered wedge is inserted into the tapered mortise that is formed at the conjoining mating edges of the interlocking section or other member.
 4. The assembly belt track of claim 2 comprises a continuous raised rib-like boss that convergently reinforces the mechanical seal. 